Bayne Thinline GRL 1110 Guide

GRL 1110
1900-0560
OPERATION AND PARTS MANUAL
ISSUED FEBRUARY 2020
CUSTOMER NAME: ____________________
SERIAL NUMBER: ____________________
1900-0560 Revision No. 003
LICENSED UNDER ONE OR MORE OF
THE FOLLOWING U.S. AND CANADIAN PATENTS:
5,503,512
4,773,812
1,327,765
5,447,405
1,335,648
5,308,211
5,333,984
5,826,485
© 2020 Bayne Premium Lift Systems .

WARNING
IF INCORRECTLY USED, THIS EQUIPMENT CAN CAUSE SEVERE INJURY. THOSE WHO USE
AND MAINTAIN THE EQUIPMENT SHOULD BE TRAINED IN ITS PROPER USE, WARNED OF ITS
DANGERS, AND SHOULD READ AND FULLY UNDERSTAND THIS ENTIRE MANUAL BEFORE
ATTEMPTING TO SET UP, OPERATE, ADJUST OR SERVICE THE EQUIPMENT. KEEP THIS
MANUAL FOR FUTURE REFERENCE
IMPORTANT SAFETY NOTICE
Proper service and repair are important to the safe, reliable operation of the Bayne THINLINE®
products. Service procedures recommended by Bayne THINLINE®are described in this
Operation and Parts Manual and are effective for performing service operations. Some of these
service operations may require the use of tools or blocking devices specially designed for the
purpose. Special tools should be used when and as recommended. It is important to note that
some warnings against the use of specific methods that can damage the product or render it
unsafe are stated in the service manual. It is also important to understand these warnings are
not exhaustive. Bayne THINLINE®could not possibly know, evaluate and advise the service trade
of all conceivable ways in which service might be done or of the possible hazardous
consequences of each method. Consequently, Bayne THINLINE®has not undertaken any such
broad evaluations. Accordingly, anyone who uses service procedures or tools which are not
recommended by Bayne THINLINE®must first satisfy himself thoroughly that neither his safety
nor the product safety will be jeopardized by the method he selects.

TABLE OF CONTENTS
GRL 1110
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Issued August 2016
Revision No: 003
........................................................................................................................................................................................2Specifications
........................................................................................................................................................................................4Installation Instructions
........................................................................................................................................................................................7Operation Instructions
........................................................................................................................................................................................8Maintenance Instructions
........................................................................................................................................................................................9Actuator Assembly Instructions
........................................................................................................................................................................................20Troubleshooting Chart
........................................................................................................................................................................................21Appendix A - Assembly Drawings and Part Numbers
........................................................................................................................................................................................221900-0560 - GRL 1110 Lifter Assembly
........................................................................................................................................................................................254800-0272 - GRL Faceplate Weldment
........................................................................................................................................................................................264800-0277 - GRL Clamp Arm Link Weldment
........................................................................................................................................................................................274800-0060 - GRL Clamp Arm Assembly
........................................................................................................................................................................................286065-2710 - GRL Control Valve
........................................................................................................................................................................................293112-1044 - GRL Clamp Cylinder Assembly
........................................................................................................................................................................................302000-1230 - Torque Bearing Assembly
........................................................................................................................................................................................312000-1338 - Lower Idler Bearing Assembly
........................................................................................................................................................................................322000-1335 - Upper Idler Bearing Assembly
........................................................................................................................................................................................33H5900001 - GRL Series Specifications
........................................................................................................................................................................................356900-0733 - Hydraulic Schematic
...................................................................................................................................................................... 37
Index

INTENTIONALLY LEFT BLANK
GRL 1110

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
1
GRL 1110
PART NUMBER: 1900-0560 REVISION NO. 003
OPERATION AND PARTS MANUAL

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Specifications
2
SPECIFICATIONS
WI-0091-A
A. Rotary Actuator - rack and pinion style design.
Rack, pinion, and shaft bearings are constantly lubricated by the hydraulic oil for extended life.
Body and caps are made of high quality ductile iron.
Pinion output shaft and racks are made of high tensile alloy steel.
The rotary actuator provides smooth motion throughout the lift cycle, which results in longer cart life with virtually no
cart damage or abuse.
B. Arm bearings are made of a composite material which provides superior compression strength along with self-
lubrication, thus eliminating the need to grease the arm bearings.
C. The THINLINE® lift unit can measure as little as 7 1/8” thick from the back of the mainframe to the front of the lifter,
depending on the types of arms used.
D. The faceplate is normally at 45 degrees in the dump position and extends 10” to 12” from the back of the mainframe into
the hopper or container opening. This places the cart or barrel 13” to 15” into the truck or container opening thus
reducing any potential spillage of materials.
E. Cycle times for safe, fast, efficient service.
6 - 8 seconds for Actuator to rotate up and down.
3 - 4 seconds for GRL arms to clamp and unclamp.
NOTICE
Cycle time is controlled by flowrate, as flowrate increases, cycle times decrease.
WARNING
Never exceed the cycle times listed above. In order to avoid injury and maintain manufacturer’s warranty never operate
outside of these recommendations.
F. Recommended flowrates are as follows:
2 to 2 1/2 GPM for 1100 series units
2 to 4 GPM for 2200 series units
G.Hydraulic pressure requirements are as follows:
1800-2000 PSI normal working pressure
3000 PSI maximum pressure

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Specifications
3
H. All lifters can be a bolt on type installation for easy, quick maintenance and less downtime.
I. All parts are manufactured and kept in stock at Bayne Machine Works, Inc. for fast response to customer request.
J. Two ( 2 ) year limited warranty from date of delivery on all units and models when properly maintained and operated
within the recommended cycle time.
NOTICE
All lift units and parts are inspected by our Quality Control Department before shipment to insure that you always receive
the highest quality available in the lift business.
For more information, please contact us at 800.535.2671 or by fax at 864.458.7519.

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Installation Instructions
4
INSTALLATION INSTRUCTIONS
WI-0236-A
The following information is intended to be a GENERAL GUIDE to installing the Bayne THINLINE® lifter on a typical refuse
truck. Before starting the installation, read these instructions completely. ALWAYS use the proper tools, lift devices, and
personal protective equipment to prevent injury while performing the installation.
NOTICE
If a Bayne THINLINE® Tap-In Kit was also acquired for this installation, refer to the installation instructions included in the
Tap-In Kit manual for more detailed information.
A. Mounting lifter(s) on the truck :
1. The truck should be emptied and cleaned before any installation. The truck should be parked on a level solid surface,
a concrete floor if possible.
2. All lights, tags, steps, etc. that will interfere with the installation should be removed and/or relocated.
3. Position the lifter(s) on the sill of the truck per Figure A-1 and mounting height drawing and tack weld in place. See
Appendix A for drawings. If using an “S” unit for bolt on applications, tack weld the mounting plate in place and
attach the lifter to the mounting plate using the 1/2” studs.
NOTICE
Tack weld only at this time so that adjustments can be made if necessary.
Figure A-1
21

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Installation Instructions
5
B. Making Hydraulic Connections :
Before attempting any hydraulic connections, turn the truck’s engine off and release all hydraulic pressure from the
system. Refer to the hydraulic layout ( Figure 2) and hydraulic schematic while performing the following steps. See
Appendix A for drawings.
Figure A-2
1. Connect the hose from the “UP” port of the rotary actuator to the “C” port of the dual hand valve.
2. Connect the hose from the “DOWN” port of the rotary actuator to the “D” port of the hand valve.
3. Connect the hose from the “C” port of the GRL control valve to the “A” port of the hand valve.
4. Connect the hose from the “UC” port of the GRL control valve to the “B” port of the hand valve.
C.Adjusting the GRL control valve :
The clamping pressure and speed of the THINLINE ® GRL lifter’s arms are controlled by the GRL control valve
mounted to the lifter.
NOTICE
It is very important to make sure the hydraulic oil is at operating temperature, and the flow rate and relief valve settings
have been properly adjusted before setting the GRL control valve pressures.
The proper flow rate and relief settings are 2 gpm at 1800 psi.
21

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Installation Instructions
6
The amount of pressure the GRL arms use to clamp the container is controlled with a pressure relief valve in the GRL
control valve. This valve is preset at the factory to operate with most containers. However, if the lifter seems to be
crushing or loosing grip on your specific containers, refer to Figure A-3 while performing the following steps to properly
adjust the clamping pressure.
1. Loosen the lock nut on the pressure relief valve in the GRL control valve.
2. If the lifter is crushing the waste container, turn the adjustment screw counterclockwise 1/4 turn. If the lifter is loosing
grip on the waste container, turn the adjustment screw clockwise 1/4 turn.
3. Repeat clamping and dumping the container, making necessary adjustments to the pressure relief valve in 1/4 turn
increments until the lifter securely holds the container without crushing it.
4. Tighten the lock nut on the pressure relief valve to secure the correct pressure setting.
Figure A-3
D.Final operation and mounting:
1. Start the truck’s engine and engage the hydraulic system.
2. Operate the lifter and bleed all air from the hydraulic system.
3. Place a cart on the lifter and operate to make sure there are no clearance problems and that the lifter engages the
cart properly. Make any adjustments to the mounting position of the lifter to ensure correct operation.
4. After locating an acceptable mounting position, complete the welding of the lifter to the truck.

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Operation Instructions
7
OPERATION INSTRUCTIONS
WI-0405-A
The Bayne THINLINE® Premium Lift System is a high quality durable cart lifter built to meet your industry’s requirements.
To insure the safety of all operators of this equipment, please read this manual carefully before operating the lifter.
FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND/OR PROPERTY
DAMAGE.
The operating stages ( Figure B-1 ) in the cycle of the cart lifter are as follows:
1. START - The cart to be dumped is rolled up to the lifter.
2. CLAMPING - The clamp arms are engaged around the cart.
3. ACTUATOR DUMP - The rotary actuator is cycled to dump the contents of the cart.
4. ACTUATOR REVERSE - The rotary actuator is reversed, returning the cart to the ground.
5. UNCLAMPING – The clamp arms are unclamped.
Figure B-1
The rotational and clamping motions of the cart lifter are controlled with the use of a dual hand valve. Moving the grabber
arm handle on the dual hand valve in the upward direction will cause the grabber arms to perform the CLAMPING stage.
Moving the actuator handle in the upward direction will cause the lifter to perform the ACTUATOR DUMP stage. Moving the
actuator handle in the downward direction will cause the lifter to perform the ACTUATOR REVERSE stage. Finally, moving
the grabber arm handle in the downward direction will cause the lifter to perform the UNCLAMPING stage.

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Maintenance Instructions
8
MAINTENANCE INSTRUCTIONS
WI-0141-A
NOTICE
The most common cause of hydraulic component failure is contamination of the hydraulic fluid ( water, chips, dirt, etc. )
The Bayne THINLINE® Lift System comes clean from the factory. If removed, be sure the hoses, cylinder and fittings are
clean before re-installing them on the unit.
Inspect your dumper on a weekly basis for loose bolts, fittings, oil leaks, etc. Tighten loose hardware as necessary and
replace necessary seals to repair oil leaks.

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Actuator Assembly Instructions
9
ACTUATOR ASSEMBLY INSTRUCTIONS
1100 Series Roller Bearing Actuator, Part Number 1122-1015 ( WI-1116-D)
Licensed under on or more of the following U.S. Patents: 4,773,812 1,327,765 5,308,211 5,333,984
NOTICE
READ INSTRUCTIONS COMPLETELY BEFORE STARTING ASSEMBLY.
Before starting the assembly of the Rotary Actuator, refer to the exploded parts drawing and parts list (Figure C-13 found at
the end of these instructions) to familiarize yourself with the individual components. Prepare a clean surface, in an area
free of blowing dust and contaminants in which to assemble the Rotary Actuator. Be sure that all parts are thoroughly clean
and dry before starting assembly.
NOTICE
All torque values given apply to clean dry threads only. Follow these directions closely when repairing the Rotary Actuator.
1. Install the piston seal load ring (13) ( Figure C-1 ) in the small groove on the head of the actuator rack (2). Place the
“square” piston seal (17) over the load ring (13) in the same small groove (a small “blunt” flathead screwdriver may
be used, taking care not to scratch or damage the seal). Install the wear ring (18) in the large groove on the head of
the rack. Using a ring compressor, firmly seat the rings on the rack before setting it aside, this will help to reverse the
effects of any stretching of the rings that occurred during installation. Repeat this procedure for the other rack.
Figure C-1
2. Install the tube seal (12) ( Figure C-2 ) and “square” tube seal backup (16) on each end of the actuator tubes (3)
( Figure C-13 ). Be sure that the “square” tube seal backup ring is toward the inside of the tubes at both ends as
shown. Press all rings firmly into the grooves. Repeat this procedure for the other tube.
Figure C-2

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Actuator Assembly Instructions
10
3. Thoroughly clean the pinion shaft (1) ( Figure C-3 ) and inner races (10) with a mild solvent and dry completely.
Spray the inner race contact area (shown in Figure C-3 ) at each end of the pinion shaft and the inside diameter of
the inner race thoroughly with LOCTITE 7649 N PRIMER. Apply LOCTITE RETAINING COMPOUND 609 around the
pinion shaft at contact area and the inside diameter of the inner races. Slide the inner races (10) on the pinion shaft
(radius end first as shown in Figure C-3) until the races seat against the gear teeth. After the races seat against the
gear teeth, twist the races on the pinion 360º to spread the retaining compound evenly. Wipe off any excess retaining
compound.
Figure C-3
4. Place the actuator body (7) ( Figure C-4 ) on the edge of the table, mounting flanges closest to the assembler with
the counter-bores facing up. Insert the pinion shaft (1) through the bore on either side of the actuator body with the
key ways facing back toward the mounting flanges and up away from the table with the center line of the key ways
pointing toward the center of the tapped hole shown in Figure C-4. Center the pinion in the actuator body.
Figure C-4

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Actuator Assembly Instructions
11
5. Coat the head portion of the racks (2) ( Figure C-13 ) with STP Oil Treatment. Install the racks, head portion up with
the teeth facing the flanges of the actuator body, into the dual set of bores in the body. Simultaneously slide the racks
into the bores so that the racks mesh with the pinion in the same position. Rotate the pinion shaft to engage the
racks into the pinion.
Figure C-5
6. Check the position of the racks in the pinion by making sure both racks seat against the actuator body at the same
time and also when the racks are seated against the body, the key ways on the pinion shaft should be facing down
toward the table and very slightly back toward the mounting flanges on the actuator body as shown in Figure C-6.
Figure C-6

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Actuator Assembly Instructions
12
7. Coat one end of the actuator tubes (3) ( Figure C-13 ) around the seal area with STP Oil Treatment as shown in
Figure C-7. Using a rubber mallet, drive the coated end of the tube onto the exposed rack until the tube end seats in
the actuator body, making sure that the seals remain in place as the tube enters the counter-bore. Repeat this
procedure for the other side.
Figure C-7
8. Install the six tie rod studs (6) ( Figure C-13 ) by screwing the short threaded end into the actuator body. Hand tighten
only at this time (the torque needed will be applied later in the procedure).
9. Place the tube cap (4) ( Figure C-13 ) on the table. Coat the sides of the two bores in the tube cap with STP Oil
Treatment. Install the cap over the tubes and rod studs with the oil port positioned to the left as shown in Figure C-
13. Using a rubber mallet, tap the tube cap over the tubes until the tubes seat in the cap, making sure that the seals
remain in place.
10.Place the tube mounting bracket (30) ( Figure C-13 ) over the two end rod studs opposite the oil port in the tube cap
as shown in Figure C-13.
11.Install the hex nuts (23) ( Figure C-13 ) and lock washers (24) on the tie rod studs. Torque the nuts to 50 ft-lb. in the
sequence shown in Figure C-8.
Figure C-8

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Actuator Assembly Instructions
13
12.Place the rack cap (5) ( Figure C-13 ) bore side up on the table and coat the edge of each bore with STP Oil
Treatment. Install the rack cap seals (14) ( Figure C-9 ) in the rack cap.
Figure C-9
13.Reposition the actuator on the table mounting flanges down, and the lower tubes facing away from the assembler.
Rotate the pinion shaft to allow 1” of the rack to protrude from the top of the actuator body. Install the rack cap with
the oil port positioned to the left hand side of the actuator opposite the bottom oil port located in the tube cap as
shown in Figure C-13. Attach the rack cap to the actuator body using the socket head bolts (22) ( Figure C-13 ) and
lock washers (26). Torque the bolts to 90 ft-lb. in the sequence shown in Figure C-10.
Figure C-10
14.Reposition the actuator so that the pinion shaft can be rotated with no obstacles. Rotate the pinion shaft to ensure
that the racks move freely. Also make sure that the key ways point perfectly straight “up” toward the rack cap and
“down” toward the tube cap at each end of the 180° stroke. If the assembly does not perform all of these functions
correctly, it must be disassembled, cleaned, and reassembled.
15.Re-center the actuator pinion in the actuator body by tapping on one end of the shaft with a rubber mallet. Install the
roller bearing (9) ( Figure C-13 ), over the pinion shaft and inner race, and into the actuator body. Repeat this
procedure for the other bearing.

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Actuator Assembly Instructions
14
16.Thoroughly clean the bearing caps (8) ( Figure C-11 ) with a mild solvent and lubricate all seal grooves with STP oil
treatment. Place the bearing caps (8) on the table (mounting surface down) and install the wiper ring (19) in the
outside groove using a rubber mallet or small press. (Avoid using tools that may damage seals or scratch
bearing cap or bearing surfaces.) Turn the bearing cap (8) over. Collapse the pinion seal (20) and carefully work it
into the groove. Use fingers to carefully press the seal completely into the groove as shown in Figure C-11. Be
careful not to score or scratch the sealing surface during the installation. Install the bearing cap seal (15) and
thrust washer (32) into their respective grooves on the bearing cap mounting surface as shown in Figure C-11.
17.Coat the bearing cap seal area and pinion seal area shown in Figure C-11 lightly with STP Oil Treatment.
Figure C-11
18.Wrap masking tape or electrical tape around the pinion to cover the edges at the keyway. Slide the bearing cap
assembly over the pinion shaft with the bearing cap seal facing toward the actuator body and the flat surface of the
flange shown in Figure C-16 facing toward the actuator mounting flanges. Press against the bearing cap until the
shoulder seats against the actuator body, making sure that the seals remain in place. Install the bearing cap bolts
(21) ( Figure C-13 ) and lock washers (25). Hand tighten only at this time. Repeat this procedure for other bearing
cap.
19.After both bearing caps have been installed, torque all bearing cap bolts to 30 ft-lb. in the sequence shown in Figure
C-12.
Figure C-12
20.Install the 90° fitting (27) ( Figure C-13 ) into the oil port on the side of the rack cap (5). Hand tighten only at this time.

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Actuator Assembly Instructions
15
21.Install the 45° bulk-head fitting (31) ( Figure C-13 ) up through the hole in the tube mounting bracket (30) bolted to
the tube cap as shown in Figure C-13. The 45° end must be pointing down away from the rack cap (5) and back
toward the mounting flanges on the actuator body. Hand tighten only at this time.
22.Install the rack cap extension tube assembly (29) ( Figure C-13 ) between the 90° fitting in the rack cap and the 45°
fitting in the tube mounting bracket as shown in Figure C-13. Tighten all connections.
23.Install the orifice plug (11) ( Figure C-13 ) into the oil port on the side of the tube cap (4), and install the 90° fitting
(27) into the oil port over the orifice plug as shown in Figure C-13. Turn the fitting so that it points down away from
the rack cap (5) and back toward the mounting flanges on the actuator body and tighten.
24.Install the cap nuts (28) ( Figure C-13 ) onto the open fittings to prevent contamination of the unit until the hoses are
installed.

GRL 1110
Issued August 2016
Revision No: 003
Printed in U.S.A.
Copyright 2016, Bayne Premium Lift Systems
Actuator Assembly Instructions
16
ACTUATOR ASSEMBLY
Figure C-13